Prism-Type Electrical Converter For The Generation, Transmission, Distribution And Suppy Of Electric Current, And Production Method Thereof

ABSTRACT

The invention relates to a prism-type electrical converter for the generation, transmission, distribution and supply of electric current, which essentially comprises two systems, namely a magnetic system and an electrical system, plus an additional thermal control or cooling system. As a result, the converter has three-phase side. The three-phase magnetic circuit forms the base of the magnetic circuit. The two-phase side is formed on the three constituent magnetic circuits thereof. 
     More specifically, the inventive converter comprises a magnetic silicon steel core which can take the form of broken or continuous spiral columns, having a circular, elliptical, cross-shaped section, etc., an Evans-type converter which is a broken spiral-type converter or a Wescord-type converter or coiled with junction. The operation of the inventive converter is based on the most commonly used system, comprising the vectorial sum of the two existing phases, such as to produce the third phase, but can be extended from two to six phases. Prism connections ETO- 120 - 2/3  and ETO- 240 - 2/3  are used as a reference, which indicate that the missing phase is formed from two supply phases, i.e. phase a by sections a 1  and a 2,  phase b by sections b 1  and b 2,  phase c by sections c 1  and c 2,  in which any phase can be generated depending on the supply phases. Therefore, if phases a and b are present, the missing phase is c, if phases b and c are present, the missing phase is a, and if phases a and c are present, the missing phase is b, such as to produce the phase that does not already exist. In this way, a three-phase output system with any voltage level supplies the three-phase voltage which, by means of another output system with any voltage level, supplies the three-phase voltage that can be used for any electrical system that is used to generate, transmit, distribute and supply electrical power. In addition, the prism conversion system can be used to obtain a balanced three-phases system with neutral that can connect any three-phase, two-phase or single-phase load from a two-phase supply with two wires, there by rendering the invention remarkable in relation to existing electrical converters which have no general application. Moreover, said prism-type connection or system has unlimited applications. Furthermore, the electrical converter is produced in a novel manner comprising the following steps consisting in: producing the magnetic core, stacking to form a three-phase assembly, forming packets, pressing same to form the power or distribution power, forming the definitive magnetic core and, finally, annealing said magnetic core, thereby defining a novel method of producing the inventive prism-type converter.

SCOPE OF THE INVENTION

This invention generally refers to the generation, transmission, distribution and supply of electric power. More specifically, this invention refers to a prism-type converter constituted by two systems, one of said systems is magnetic and the other one electric, and in addition it includes a cooling or thermal control system due to the fact that said converter has a three-phase side, where the magnetic circuit is based on the three-phase magnetic circuit and the two-phase side is built on the three magnetic circuits that form it, that is, it is constituted by a silicon steel magnetic core that may be of a column type with sections shaped in any form, of a continuous core, or it can be rolling, columned, or shielded, etc. It can also be of an Evans type just like the above but broken, or it can be of a Wescord type but coiled with junctions. Its operation principle is based on the vectorial sum of the two existing phases to produce the non-existing third phase which makes it different from all the other electric converters such as the Scott type. The prism type, an open Delta, of this invention creates a third phase as the output of this conversion, due to the fact that the three phases are created therein through the digital commutation from a direct current source.

BACKGROUND

To date, we are familiar with two or three-phase electric converters, such as those invented in the XIX Century with the developments called Scott and Open Delta; from which the Scott system cannot be applied to the present electric nets, because said nets are only used to feed from three to two phases in electric melting furnaces, and the reverse application of two or three phases is not possible as illustrated in FIG. 1. The open Delta System is still in use and it provides three-phase power in a distribution system but its efficiency is only of 57.7% (Chester L. Dawes), illustrated in FIG. 2 herein.

Lastly, it provides unbalanced neutral voltage and also unbalanced currents.

At present, there are two or three-phase electric converters only for low voltage electric or electronic engines. The one with the best operating performance is electronic but it is limited by the fact that it only works from low voltage to low voltage and its use is extremely expensive, in addition, its application depends on the nature of the connected charge.

The other electric converters called prism as the one shown in FIG. 5, a practical example of how it is built with a silicon steel magnetic core that may be of a column type with sections shaped in any form, of a continuous core, or it can be rolling, columned, or shielded, etc.; it can also be of an Evans type just like the above but broken, or it can be of an Wescord type but coiled with junctions.

The difference of the converter in this invention regarding its operation is that it is based on the vectorial sum of the two existing phases so that they produce the third non-existing phase. That is; a prism-type converter, in contradistinction to other electric converters, such as the Scott or open Delta converters creates a third phase as the result of this conversion, because in the electric converter, for example, the three phases are created through digital commutation from an electric current source.

DESCRIPTION OF THE INVENTION

Thus, the purpose of this invention is to provide a new and improved prism-type electric converter from two to three phases from high voltage to high voltage, from high voltage to medium voltage, and from medium voltage to low voltage and reversible.

Another more specific purpose of this invention is to provide a prism type electric converter with improved conversion efficiency.

Yet another purpose of this invention is to provide a prism type electric converter that can be applied to any electric system from generation, transmission, distribution to supply of electric power.

An additional purpose of this invention is to provide a prism type electric converter built with two systems, one of which is magnetic and the other one electric having a cooling or thermal control system due to the fact that the converter has a three-phase side.

And still another purpose of this invention is that the magnetic circuit of the converter has as its foundation the three-phase magnetic circuit and it also has a two-phase side that is constructed in the three magnetic circuits that form it.

The purposes mentioned above and other purposes that shall become evident as this invention is described and that are fulfilled through the prism type electric converter which is a universal converter because it is applicable to all of the electric systems from generation, transmission, distribution to supply systems, and which in addition provides very high efficiency up to 98%, that is, almost 100%, perfection in efficiency, depending on the power, totally balanced in voltages between phases and between phases and neutral can feed any type of charge such as: one phase, two-phase or three-phase, any power is higher through supply to Scott or open Delta type electric converters and because of its application and the fact that it is universal to low voltage electric and electronic converters.

It can be seen that in the alternating current distribution systems used in all the countries in the world as shown in FIG. 3 from a normal three or four threads three-phase line a three-phase medium voltage service is obtained.

Nevertheless, in small cities, in towns and suburban zones and in the country the use of three-phase lines is not profitable for electric power generating companies because the number of users is not enough to compensate for the installation cost. Consequently, in some countries in Europe and in the United States the option is to install two wire two-phase nets and provide one phase residential services and when a three-phase service is required the net is completed but it is charged to the user making the cost very high for the final user because three-phase electric power is in great demand. This system does not fulfill the needs of the user fully because it must be complemented for example with systems that work especially well or efficiently but at a very high cost. One of those systems is that used by the CFE in Mexico called open Delta that provides an unbalanced three-phase service but with a low efficiency percentage, if only 57.7% is used with two one phase transformers, as seen in FIG. 2.

This same unfulfilled need, has also caused the proliferation of capacitive converters with a very selective application to electronic converters that have a very high cost for power higher than 15 KVA that are only used now at a low voltage so the cost of a one phase feeding substation must be added to the cost of said converters.

FIG. 4 shows the proposed answer for distribution systems that can solve the problem all over the world because medium voltage nets can be built in two wires and the power companies can solve the expansion problem and at first the charges could be one phase charges, but in contrast with the traditional distribution system any user who requires a three-phase service can obtain it from the proposed converter, in its application from medium voltage to low voltage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 describes the Scott connection invented late in the XIX century.

FIG. 2 describes the open Delta connection invented late in the XIX century.

FIG. 3 describes the alternating current Electric distribution system of general use to generate, transmit and distribute alternating electric power.

FIG. 4 describes the electric system in the application of the prism type electric converter of this invention.

FIG. 5 describes the types of cores of present practical use; that is, as the present prism type electric converter is constituted.

FIG. 6( a) vectorially describes the electric system or ETO 120-2/3 of the prism type converter (prism connection) of this invention.

FIG. 6( b) illustrates the prism connection ETO-240 2/3 of this invention

FIGS. 7( a) and (b) describe the core of the prism-type ETO 240-2/3 electric connection of the coil, of the prism-type converter of this invention, and show the application to the column and shielded Wescord cores, respectively.

FIG. 8 describes the possible physical arrangement of the prism system of the prism type converter of this invention.

FIG. 9 describes the exterior physical presentation of the prism type converter of this invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 describes the Scott connection invented late in the XIX century, one of the first two—three-phase electric converters invented with the developments called Scott and open Delta, where the Scott system cannot be applied to the present nets that are used only to feed from three to two phases in electric melting furnaces and where the reverse application from two to three phases is not possible.

FIG. 2 describes the open Delta connection in force at present that provides three-phase power in distribution systems but the efficiency of which is 57.7% (Chester L. Dawes). FIG. 2 is an illustrative layout of this open Delta connection that also presents unbalanced voltages at neutral and also unbalanced currents.

FIG. 3 describes the distribution electric system of a present general use to generate, transmit and distribute alternating current power where the alternating current distribution electric system is used all over the world and which shows that from a normal three-phase line in three or four wires a three-phase medium voltage service is obtained.

FIG. 5 describes the types of cores; that is, how the present prism-type electric converter is constituted, where the silicon steel magnetic core is shown, said core can be of a column type with section in any shape; that is, round, elliptical, cross-shaped, etc. But, it can also be (not shown) of an Evans type like the above but broken, of a Wescord type or rolled with coil with junctions. Its operational principle is based on the vectorial sum of the two existing phases so that they produce the third non-existing phase, in contradistinction to other electric converters, such as the Scott or open Delta converters creates a third phase as the result of this conversion, for example in the electric converter (not shown) the three phases are created through digital commutation from an electric current source. Up to know only the previous data of the electric converters related to the prism type electric converter of this invention have been described.

FIG. 4 describes the possible electric system for the innovative application of the prism type electric converter of this invention, as the proposed answer for distribution systems and thus this representation is explained for a general problematic, due to the fact that low voltage nets can be constructed on two wires, therefore, electric power companies would solve the expansion problems because if the charges are one phase charges, with the traditional distribution system (not shown) any user requiring a three-phase service, could obtain it from the electric system of the proposed converter, in its medium tension to low tension distribution application.

FIG. 6( a), vectorially describes the electric system of the prism-type converter (prism connection) or ETO 120-2/3 shown in this invention with the precise details of prism connections, which means that it is the prism converter connected to 120° electric that converts from two (2) to three (3) phases, as can be seen in the figure. The phase is formed by two sections for example phase a by sections a1 and a2, phase b by sections b1 and b2, and phase c by sections c1 and c2, where the general phases can be any one of them a, b, or c, where in said FIG. 6, it can be noted that phases a and b form phase c. The section of phase c1 is formed by a1 and b1, the section of phase c2 is formed by a2 and b2. When phase c is formed this originates the corresponding phases, a with s1, b with s2 and c with s3. The angular displacement obtained in these phases is 120° E (electric degrees), just as in a typical three-phase system, and it generates symmetric voltages between phases and between phases and neutral. For example, for Mexico the feeding voltage can be 13200, 23000, or 34500 volts, the most common output shall be 220 volts between s1 and s2, 220 volts between s2 and s3, 220 volts between s1 and s3 and 127 volts between s1 and n, 127 volts between s2 and n, and 127 volts between s3 and n. The input voltage values can be of any common or special use value or of a special value on the two-phase side, and on the three-phase side the voltage values can be of any common or special use value.

FIG. 6( b) illustrates the prism connection ETO-240 2/3, shows that it operates just as in FIG. 6( a), the difference is the angular displacement of the two input vectors that in this case have a 240° E (electric degrees) displacement.

FIGS. 7( a) and 7(b) describe the core-coil arrangement of the prism type electric connection ETO-240-2/3 of the prism-type converter of this invention, and show the application of the column type core and of the shielded wescord core respectively, where the winding is formed by three sections, two medium voltage sections and one low voltage section connected in the way described in FIGS. 6( a) and 6(b) according to the input voltage equation for balances systems which is:

P_(ENT)=2Vphase Iphase

-   -   Where PENT=Voltage input in watts     -   Vphase=phase voltage in volts         I phase=phase electric current in amperes

And in accordance with the output voltage equation which is:

P_(SAL)=3Vphase Iphase

-   -   Where PSAL=Voltage output in watts     -   Vphase=phase voltage in volts     -   I phase=phase electric current in amperes

FIG. 8 describes the possible physical arrangement of the prism system of the prism type converter of this invention.

Finally, FIG. 9 describes the exterior physical presentation of the prism type converter of this invention, where said converter is built as follows: the magnetic core is manufactured conventionally; that is, the broken column cores are made by means of a cut or the rolled sheet, these cuts are made at 90° or at a 45° angle depending on the design of the core. Once the cuts have been made, they are piled up so that they form a three-phase set that can be shaped as a star, in a Delta or on Planes as shown on FIG. 5. This type of cores can also be manufactured in a continuous form with few cuts, thus these are spiral cores, once the form of the section is decided. Said form can be round, in steps, elliptical, cross-shaped, etc., three round packages are formed by means of perfectly compact winding, once this stage has concluded they are pressed to give them the desired shape designed according to the distribution voltages, or to higher voltages, and finally the definitive core is formed as shown in FIG. 5. During said process mechanical efforts that alter the molecular grid and cause magnetic losses can be found during the machining. Said losses can be reduced submitting the core to an annealing process.

The Evans core is the same but with cuts that form two assembled halves after the corresponding coils have been mounted.

Another quite spread method at present is the one called rolled or Wescord that consists in making four broken sheet packages called major harness and minor harness; that is, the round sections are formed after the cut by means of winding, compacting and pressing to give them the definitive shape, also submitting them to an annealing process to minimize magnetic losses. These are some of the magnetic cores that form the three-phase magnetic circuit used to build the prism-type converter of this invention.

Anyhow, the electric part is manufactured in three columns, each for each one of the phases in an enfolding electric circuit (spiral columns, Evans, etc.) or in an enfolding magnetic system (shielded Wescord, spiral shielded, broken shielded, etc.). The coils are built with windings considering the number of turns required for each two-phase or three-phase voltage, where the winding for each phase is formed by two actions per phase for the two-phase side, one section per phase for the three-phase part as in FIGS. 7( a) and 7(b).

Then, any two-phase voltage or three-phase high voltage, medium voltage or low voltage can be used; any current density typical in electric conductors that do not surpass their thermal limits according to the kind of insulation can be used; in this case the magnet wires, the plates, the sheets and the insulation used in general worldwide in accordance with international standards in this matter can be used.

Therefore, this invention in the distribution field represents a very important benefit for power generating companies because it saves 33% of the installation equipment in the distribution net, there are more users with two-phase lines and the benefit can be extended anywhere, such as medium size communities or the country where they can potentially provide the three-phase service to whoever might need it. This benefit can also be extended to the transmission and to the generation of electric power. 

1. Prism-type electric converter to generate, transmit, distribute and supply electric power consisting of a magnetic system, an electric system and a cooling system. Due to the fact that the converter has a three-phase circuit, the magnetic circuit is based on the three-phase circuit and the two-phase circuit built by the three magnetic circuits that form it characterized because the converter is vectorially connected at 120° and 240° electric degrees that converts form two to three electric phases, (between ETO 120-2/3 and ETO 240-2/3), where the phase if formed by two sections; that is, phase a by sections a1 and a2, phase b by sections b1 and b2, phase c by sections c1 and c2, and the generated phase can be anyone of them phase a, b or c, as the section of phase c1 is formed by a1 and b1, the section of phase c2 is formed by a2 and b2, and when the section of phase c is formed it originates the corresponding phases, phase a with s1, phase b with s2 and phase c with s3, the angular displacement of this phases is between 120° E (electric degrees) and 240° E (electric degrees), generating symmetrical voltages between phases and between phases and neutral, there also being feeding voltages and output voltages between s1 and s2, between s2 and s3, between s1 and s3, between s1 and n, s2 and n and between s3 and n, in addition the input voltage values can be any value of a common or special use in the two-phase side or in the three-phase side.
 2. Electric converter such as the one in Clause 1, characterized because it can be formed from a silicon steel magnetic core that can be of a column type having a section of any shape whether round, elliptical or cross-shaped, spiral or broken at 90° or 45°.
 3. Electric converter such as the one in Clause 1, characterized because it can be formed from an Evan type converter which is like the spiral type converter but broken.
 4. Electric converter such as the one in Clause 1, characterized because it can be formed from a Wescord type converter or rolled but with junctions.
 5. Electric converter such as the one in Clause 1, characterized because its operation principle is based on the vectorial sum of the two existing phases to produce the non-existing third phase.
 6. Electric converter such as the one in Clause 1, characterized because the electric conversion can be extended from two to six phases.
 7. Electric converter such as the one in Clause 6, characterized because the generated phase can be any depending on the input phases.
 8. Electric converter such as the one in Clause 1, characterized because it allows the user to obtain a three-phase system balanced with neutral to connect any three-phase, two-phase or one phase charge from a two-phase input with two wires.
 9. Electric converter such as the one in Clause 1, characterized because it is of a general application such as in generators, engines, electric melting furnaces, electric installations and other special electric equipment.
 10. Electric converter such as the one in Clause 1, characterized because it converts voltages from IVA or less up to hundreds of MVA, in any voltage, in any magnetic configuration of three-phase cores, level, delta, star, independently.
 11. Electric converter such as the one in Clause 1, characterized because the electric system is built in three columns, one for each phase.
 12. Method to manufacture a prism-type electric converter to generate, transmit, distribute and supply electric power, characterized by the steps to: a) Manufacture the magnetic core, b) Pile up to form a three-phase set as a star, delta, level or continuous, (spiral, round, steps, elliptical, cross-shaped), c) Form packages by means of compact winding, d) Press to shape according to the distribution voltages or to the voltages, e) Form the definitive magnetic core f) Annealing the nucleus if the molecular grid was altered due to mechanical efforts during machining
 13. Method to manufacture a converter, like the one on Clause 12 above, the characteristic of which is that the broken column type cores are made by cutting the rolled sheets at a 45° or 90° angle or continuous spiral.
 14. Method to manufacture a converter, like the one on Clause 12 above, the characteristic of which is that the magnetic nucleus can be formed with an Evans type nucleus with a broken nucleus.
 15. Method to manufacture a converter, like the one on Clause 12 above, the characteristic of which is that the magnetic nucleus can be formed with a Wescord nucleus consisting of four broken sheet packages called major harness and minor harness which form the round sections after cutting and compacting the coils, they are pressed to give them their definitive shape and they are submitted to an annealing process in order to minimize losses.
 16. Method to manufacture a converter, like the one on Clause 12 above, the characteristic of which is that the electric part is built in three columns, one for each of the phases of an enfolding electric circuit or an enfolding magnetic circuit.
 17. Method to manufacture a converter, like the one on Clause 12 above, the characteristic of which is that the coil is built according to the number of turns for each tension: two-phase or three-phase.
 18. Method to manufacture a converter, like the one on Clause 17 above, the characteristic of which is that it is formed for each phase: two sections per phase for the two-phase part, and one section per phase for the three-phase part. 